In this issue, our leading article is about control. Control is key to optimnizing energy consumption, maximizing production and realizing energy savings when drying paper or paperboard on the machine.

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Fulton Systems Pro-Dry is the new way to control your dryer steam system. Pro-Dry will give you more control and accountability than you have ever seen in a new or retrofitted application. 

With Pro-Dry, your vision becomes your machine. Pro-Dry software is capable of taking your P & ID or flow sheet directly to your machine. The design parameters you set in the office are directly transferred to your operating system—no compromises, no modifications. What you want is what you get.

We have a custom process to assure your intentions end up on your machine.

This starts with your process. Your personnel review your needs with our professionals. We go over the intent of your process design, establish criteria and battery limits. A preliminary schedule is reviewed.

Taking your ideas and our expertise, our team prepares design concepts and starts the iterative design process with your team. We must exit this phase with your design requirements fully reviewed and accepted by all parties involved, especially you.

We’ll take a bit of time to make sure what you want is what is possible. Then we will ask you to approve the design.

Next, your project goes into our production and testing schedule. We assemble the components and software according to the approved design parameters.

Once the system is assembled in our shop, it is tested there. If you wish to witness testing, you are more than welcome.



Thoroughly tested, we ship the system to your mill for installation. Our rigid process is designed to minimize machine downtime for you. Ramp up with the new system is quick and easy.

Pro-Dry and Fulton Systems is much more, however. Please refer to our website, www.fultonsystems.com, for more ways to enhance your dryer steam and condensate system.

For 130 years, inventors have been trying to build an automobile without a steering wheel. Now, in 2025, it seems as though they are about to acheive their dream of control without continuous human input.

Well, Fulton Systems is already there with steam control on your dryer section. The Pro-Dry System is simple and can be independent of your overall steam control. Check it out if you want worry free dryer steam control now.

Customerservice@FultonSystems.com

The modern control valve dates to 1880, when William Fisher, an engineer at the city waterworks in Marshalltown, Iowa, worked continuously for over twenty-four hours to manually maintain constant discharge pressure on a steam-driven water pump. Constant manual regulation was required because of the extreme demand made on the system to supply water to fight a fire. From this experience, Mr. Fisher invented the constant-pressure pump governor and founded the Fisher Controls Company to manufacture his regulator.

Two centuries after the first industrial revolution, the white plumes from industry’s chimneys are still the symbol of industry, fostering societal prosperity, but they are also a symbol of environmental pollution.

Key Concepts Review

Paper Machine Dryer Drainage: Understand why proper drainage is crucial in paper production.

Differential Pressure: Define differential pressure in the context of dryer drainage and explain its role in condensate removal.

Blow Through Steam Flow: Define blow through steam flow and explain its role in condensate and non-condensable gas removal.

Syphons: Describe the function of syphons in dryer cylinders and the different types discussed (low speed stationary, high speed stationary, rotary).

Pressure Loss: Understand the different factors contributing to pressure loss within the syphon (accelerational, gravitational, centrifugal).

Playing Field: Explain the concept of the "playing field" in relation to operating conditions and its impact on drainage.

Control Strategies: Describe the two main control strategies discussed: differential pressure control and blow through flow control.

Dual Monitoring with Selective Controls: Understand the benefits of monitoring both differential pressure and blow through flow.

Quiz

1. Explain the primary purpose of controlling dryer drainage in a paper machine. Why is this process important for efficient paper production?
2. Define differential pressure as it relates to steam dryer cylinders. How does maintaining a sufficient differential pressure contribute to effective condensate removal?
3. What is blow through steam flow, and what are the two main substances it helps to remove from the dryer cylinders?
4. Describe the key difference between low speed stationary syphons and high speed stationary syphons in terms of their design and typical application.
5. Briefly explain how an increase in blow through rate typically affects the pressure loss within the syphon. What is the underlying reason for this change?
6. What does the term "playing field" refer to in the context of dryer operation? Explain how different operating conditions can influence this "playing field."
7. Describe how differential pressure control is typically implemented to manage dryer drainage. What parameters are usually monitored and adjusted?
8. Explain how blow through flow control works to manage drainage. What is the primary mechanism used to regulate the blow through rate?
9. What are the advantages of implementing dual monitoring of both differential pressure and blow through steam flow with selective controls?
10. In situations where high condensing loads and typically lower blow through rates are common, which of the two main control strategies (differential pressure or blow through flow) might be considered a less attractive primary control strategy, according to the text? Briefly explain why.

Answer Key

1. The primary purpose of controlling dryer drainage is to efficiently remove condensate and non-condensable gases from the dryer cylinders. This is important for maximizing heat transfer efficiency, ensuring uniform drying, and preventing operational issues like flooding.
2. Differential pressure in steam dryer cylinders is the pressure difference between the steam supply header and the condensate header. Maintaining sufficient differential pressure provides the driving force needed to push condensate out of the cylinders through the syphons.
3. Blow through steam flow is a continuous flow of steam through the dryer cylinders, beyond what condenses into water. It helps to remove both the liquid condensate and non-condensable gases (like air) that can hinder heat transfer.
4. Low speed stationary syphons are lightweight devices supported by a pipe connected to the steam joint and are oriented vertically downward in the six o'clock position. High speed stationary syphons are heavier, rigidly supported devices that require cylinder support for installation and are also oriented down in the six o'clock position.
5. An increase in blow through rate generally leads to an increase in frictional pressure loss within the syphon. This is because a higher flow rate results in greater friction between the moving fluid (steam and condensate) and the inner walls of the syphon.
6. The "playing field" refers to the range of acceptable operating conditions for the dryer section, characterized by combinations of differential pressure and blow through rate that ensure effective drainage. Different operating conditions, such as machine speed and steam supply pressure, can shift this optimal operating range.
7. Differential pressure control typically involves maintaining a set pressure difference between the steam supply and condensate headers using control valves. This ensures sufficient driving force for condensate removal, often adjusting based on the pressure in the condensate header.
8. Blow through flow control manages drainage by regulating the amount of steam allowed to pass through the dryer cylinders without condensing. This is typically achieved using a control valve in the blow through line, often adjusted based on measurements of the blow through rate or related parameters.
9. The advantages of dual monitoring with selective controls include additional operating information for improved troubleshooting and maintenance, additional comparative data for various grades and speeds, maximum flexibility to suit operational speeds, and operational back-up control system for increased reliability.
10. Blow through flow control might be a less attractive primary control strategy in situations with high condensing loads and typically lower blow through rates. This is because a low blow through rate may not be sufficient to effectively remove condensate under high condensing conditions, potentially leading to inadequate drainage.

Essay Format Questions

1. Discuss the interplay between differential pressure and blow through steam flow in achieving optimal dryer drainage. Analyze how manipulating one parameter can impact the effectiveness of the other and under what conditions one might be prioritized over the other in a paper machine drying section.
2. Compare and contrast the different types of syphons discussed in the text (low speed stationary, high speed stationary, and rotary), focusing on their design characteristics, typical operating speed ranges, and the factors influencing their selection for a particular dryer application.
3. Explain the concept of the "playing field" in dryer operation and analyze the factors that can cause shifts or changes in this optimal operating range. Discuss how understanding the "playing field" can help optimize dryer performance and troubleshoot drainage issues.
4. Evaluate the two primary control strategies for dryer drainage discussed in the text: differential pressure control and blow through flow control. Discuss the advantages and potential limitations of each strategy and under what specific operating conditions each approach might be most effective.
5. The text highlights the benefits of dual monitoring of differential pressure and blow through steam flow. Elaborate on these advantages, explaining how having data on both parameters can lead to improved control, troubleshooting, and overall efficiency in the paper drying process.

Glossary of Key Terms

Condensate: Water formed by the condensation of steam within the dryer cylinders.

Differential Pressure: The pressure difference between two points in a system, in this context, typically between the steam supply header and the condensate header of the dryer section.

Blow Through Steam Flow: The portion of steam that enters the dryer cylinder and passes through without condensing, carrying away condensate and non-condensable gases.

Syphon: A device located inside the dryer cylinder used to remove condensate.

Stationary Syphon: A type of syphon that remains in a fixed angular position within the rotating dryer cylinder.

Rotary Syphon: A type of syphon that can adjust its internal position relative to the rotating dryer cylinder.

Pressure Loss: The reduction in pressure as a fluid (steam or condensate) flows through a system component, such as a syphon.

Playing Field: The range of acceptable operating conditions (combinations of differential pressure and blow through rate) that result in effective dryer drainage.

Steam Supply Header: The main pipe that delivers steam to the dryer cylinders.

Condensate Header: The main pipe that collects the condensate removed from the dryer cylinders.

Non-Condensable Gases: Gases (such as air) present in the steam system that do not condense into liquid water and can impede heat transfer.

Thermocompressor: A device that uses high-pressure steam to entrain and compress lower-pressure steam, often used in blow through systems.

Orifice Plate: A thin plate with a hole in it, used to restrict flow and create a pressure difference for measurement or control.

Control Valve: A valve used to regulate the flow rate or pressure of a fluid in a system.